Enhancing microstrip patch antenna performance through CNF-modified dielectric substrates and 3D printing techniques

Purpose This research investigates the impact of carbon nanofiber (CNF) incorporation on the dielectric properties, mechanical integrity and performance of microstrip patch antennas. This study examines how varying CNF concentrations affect key electromagnetic parameters like dielectric constant and loss tangent while assessing nanocomposite mechanical characteristics. Leveraging material modification and additive manufacturing, this study aims to enhance antenna performance, tunability and manufacturability. Design/methodology/approach Antenna substrates were fabricated using fused deposition modeling with acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) containing 0.05%–2% CNFs. Dielectric properties were analyzed, while scanning electron microscopy assessed surface homogeneity and CNF dispersion. Mechanical tests evaluated yield strength and toughness. Antennas were tested over 1–15 GHz, focusing on reflection coefficient (S11) and voltage standing wave ratio (VSWR). Findings CNF-modified substrates exhibited tunable dielectric properties (1.98–2.21 dielectric constant). Scanning electron microscopy confirmed improved dispersion. ABS-based antennas with 2 Wt.% CNFs showed optimal S11 and VSWR in the 2–4 GHz range. While CNFs slightly reduced ABS yield strength, they enhanced toughness, demonstrating the potential of customized dielectric materials for high-performance antennas. Originality/value This study introduces a novel microstrip patch antenna fabrication method using fused deposition modeling with customized dielectric materials. Unlike conventional approaches, it enables precise dielectric tuning via controlled CNF incorporation. ABS and PC were chosen for their dielectric stability, mechanical strength and three-dimensional printing compatibility. Investigating CNF concentrations (0.05%–2%) provides insights into dielectric behavior, mechanical properties and processing constraints. Enhanced antenna performance, especially in the 2–4 GHz range, underscores material composition’s impact. This scalable approach supports next-generation communication systems, including IoT, 5G and aerospace applications.